Extruded Corner Bracket Assembly for Variable Panel Thickness
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Solution Overview
Problem
Existing corner bracket designs are not easily manufacturable or assembleable for a wide range of structures, do not support varying material thicknesses and compositions, and often require assistance for assembly, limiting their versatility in constructing different structures like boxes, planters, and benches.
Innovation Solution
An extruded corner bracket with a body, wings, and slots that can accommodate different lengths and thicknesses of planar materials, featuring a slot for non-rotatable nut retention and bolt housing, along with clamping blocks and fasteners, allowing for easy assembly and use in various structures, including kits for specific applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional corner bracket designs are used, then structural support is provided, but manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The corner bracket is divided into modular components including an extruded corner member with integrated slots, separate fasteners, and optional clamping blocks. This segmentation allows each component to be manufactured independently using standard extrusion and machining processes, simplifying manufacturing while maintaining structural integrity through the standardized connection interface.
Solution Approach 2:
The extruded corner member is designed with universal slots that can accommodate various fastener types and configurations, allowing the same corner bracket design to support different planar materials of varying thicknesses and compositions. This multi-functionality reduces the need for multiple specialized bracket designs, easing manufacturing across product lines.
2Ease of operation
If traditional corner bracket designs are used, then corner support is provided, but assembly requires assistance and is difficult
Solution Approach 1:
The corner bracket design enables single-person assembly through self-aligning features where the extruded slots guide fastener insertion, and the clamping blocks automatically position themselves to secure planar materials. The standardized interface allows the assembler to work independently without requiring a second person to hold components in place or provide complex alignment.
Solution Approach 2:
The extruded corner member is pre-formed with precisely positioned slots during manufacturing, eliminating the need for on-site drilling or alignment adjustments. This preliminary preparation of connection points simplifies the assembly process, allowing users to simply insert fasteners without requiring specialized tools or assistance.
3Adaptability or versatility
If traditional corner bracket designs are used, then structural support is provided, but versatility across different structures and materials is limited
Solution Approach 1:
The corner bracket system incorporates adjustable elements where clamping blocks can be positioned at different locations along the extruded member, and fasteners can be selected based on material requirements. This dynamic adjustability allows the same basic corner bracket design to adapt to various structures like boxes, planters, and benches, as well as different materials including wood, metal, and plastic, without requiring completely different designs for each application.
Data Source
AI summary
An extruded corner bracket is provided, the corner bracket comprising a length; a body extending the length; a pair of wings extending the length and extending outward from the body to define, with the body, an outer right angle and a pair of inner right angles, the inner right angles being normal to each other, each inner right angle having a first face and a second face; and a slot within the body and extending the length, the slot for slidably, non-rotatably retaining a nut and for housing a distal end of a bolt, the slot including an elongate opening defined by a distal edge of each first face. A corner bracket assembly, rectangular structures using the corner bracket assembly and a kit are also provided.